Furnace wall construction



-L" H' "OSBE'N 2,328,907

URNACE WALL CONSTRUCTION Original Fi-ledet. 18;;1959 4 sheets-sheet 2 X l. l

Sept. 7, 1943. H. HosBl-:IN

-- FURNACE WALL cJoNsTlQcTIoN original Filed nt. 18,-'1959 4 Sheets-Sheet 4 Patented Sept?, 1943 vatraso? vUm'rlsl) STATE-s PA'riazN'r oFFicE EUBNACE cons itucnon v Glencoe, 111..'Y :nor to M. Il. Y

Dctrick Company, of Delaware Chicago.

l., a corporation original application october 18,* 1939, serial N0.

Divided and this application August C14, 1941, serial 10.406.113 Y 'i claims. (cuz-101) a wall which includes the step of applying a backing of plastic material having finish characteristics for substantially enclosing the metal sup-y porting members and eliminating substantially all air spaces in the wall.

A further important object of the invention is the provision of a. method of erecting such a wall from the exterior of the furnace.

Another important object of the invention is `the provision of a method of constructing such a wall by separately and successively erecting the metal supporting structure, the refractories, and the insulation material. l

A further object of the invention is the provision of a method of constructing a furnace Wall which includes the steps of applying an excess of plastic insulation material to the rear surfaces of the refractory members and forcing an outer. casing against the outer surface of such plastic material.

Numerous other objects and advantages of the I invention will be apparent as itis better understood from the following description, which, when taken in connection with -the accompanying drawings, discloses a preferred, embodiment thereof. y

In the drawings,

Figure 1 is a rear elevational view of a furnace wall embodying the features of the invention with parts broken away and partly in section to show the/interiorconstruction thereof; -V

Fig. 2 is a transverse, vertical section taken substantially on the line 2 2 of Fig. `1; 'n

Figs. 3 and 4 are .perspective views'of one of" the refractories or titles employedtaken from the top and bottom thereof, respectively] Fig. 5 is' a perspective view of one ofthe auxiliary hanger members of Figs. r1 and 2;

Fig.V 6 is a perspective view of one of the horizontal retaining members of Figs. land 2;

Fig. 7 is a perspective view of one of the Vmain efraciiry supportingl hanger members Vof Figs.

and v Fig. 8 is a. transverse, horizontalwsectlon through a modified construction offurnace wall embodying the features of the invention;

9 is a transverse, vertical sectional view of the wall of Fig. 8;

Fig. 10 is a perspective view of a modified form of auxiliary hanger member employed in the wall of Figs. 8 and 9;

Fig. 11'is a perspective view of one of the horn` zontal retaining members of thewall of Figs. 8 and 9; and l Fig. 12 is a perspective view of one of the modified main refractory supporting hanger members of Fig. 9.

Referring more particularly to Figs. 1 to 7 ofI the drawings, reference numeral II indicates a vertically disposed frame member, of which a plurality are provided in spaced relationship longitudinally from eachother in the direction of the wall. A plurality of horizontally disposed frame or supporting members I2 are secured by means of bolts I3 to the vertical frame members II `to provide a skeleton frame for the wall having any suitable or desired type of foundation therefor. The frame members II maybe of any suitable shape, while the horizontal'frame members I2 are provided with longitudinally extendlng recesses I4 in their inner surfaces (Fig. 2) and longitudinally extending, marginal recesses I5 and IS along the upper and lower edges of their rear surfaces (Figs. 1 and`2). The recess or channel I4 is positioned a short distance below thehorizontal center line of each of the frame members I2, and the latter are preferably provided with a plurality of elongated apertures I'I extending therethrough substantially on the centerline thereof. The apertures il are spaced longitudinally of the members I2 for the purpose of accommodating the bolts i3 and for another purpose to be later more fully described.

:The inner surface ofK the instant furnace4 wall (to the rear of Fig. 1 and to the rightln 1 Fig. 2) comprises a plurality of refractory tiles or'bricks, indicated generally by reference nuY meral'fl; 'Referring `more particularly to Figs. 3 and 4, each ofthe bricks cr tiles I9 is inthe shape of a` rectangular parallelogram having front and rear "surfaces i9 and 2I,respectively, top and bottoni surfaces22 and 23, respectively, and right and left end surfaces Eiland 25,re-

spectively. It will be understood that the re'- fractory vI3 is being viewed from the rear in '.Etigs.`

3 and 4. The ltop surface 22 is provided with a lward surface of the frame members. ward end, the hanger member 4I is provided with longitudinal groove 26 disposed adjacent the rear surface 2I, and the lower surface 23 is provided with a similar groove which comprises three separated portions 2J, 28 and 29. The grooves 21. 28 and 29 are in longitudinal alinement with each other and in vertical alinement with the groove 26. The rear surface 2l of the refractory is cut access to the grooves 21, 28 and 29, respectively, from the rear of the brick. The upper surface 22 of the refractory I8 is also provided with a' longitudinal groove 34 extending parallel to the groove 26 adjacent the front --surface I9. The groove 34 is in vertical alinement with a groove 85 extending in communication therewith along away at its lower edge at 3|, 32 and 33 to provide the left hand end 25 of the tile. The grooves 84 and 85 are appreciably more shallow than the grooves 26 to 29. The right hand end 24 of the tile is provided with a. flange 36 which is in vertical alinementwith thegrooves 34, 35 and extends outwardly from the -end surface a disl tance substantially equal to the depth of the latter grooves.` 'I'he bottom surface 23 is provided with'a similar'rib portion 31. -1

When the/refractories I8 are laid in the man ner shown in Figs. 1 and 2 to form the inner portion of thewall, the bricks of adjacent hori- 1 and-each of the separate tiles will aid in maintaining the alinement. p

Means are provided for sectionally supporting the several refractories I8 and for `facilitating the erection and .removal and replacement thereof from the rearof the wall. Removably mounted upon the several horizontally disposed frame or supporting members I2 are a plurality of main refractoryl supporting hanger members, indicated generally by reference numeral 4I. As will be seen .in Figs. 2 and '7; each of the hanger members 4I comprises a main `body portion which isdisposed transversely of the wall and terminates at the rear adjacent the upper end thereof in a downwardly extending hook member 42. The rear edge'of the hanger member 4I is cut away at 43 adjacent and below the hook 42, and terminates at its lower end in a rearwardlyextending pad 44. With such configuration, the hanger member 4I is adapted to be removably mounted upon a horizontal frame member I2 with the hook 42 engaging within the upper channel or groove I5, the cut-away portion 43 providing clearance for the upper part of the frame member I2, and the pad 4,4 resting against the for- At its forones adjacent thereto in proper a forwardly extending flange 45 which terminates in upwardly extending, longitudinally spaced lugs 46. Each of the hanger members 4I is adapted to support a plurality of refractories I8. eight in number for example, although engaging only the lowermost one of this group of refractories. Such engagement is had only between the cut-away portion `32 of the tile and the flange 45 of the hanger member, and between member.

. `member 4 I the lugs 46 and the groove 28 (Fig. 2), if the hanger 4I is positioned to engage the central part of the lowermost refractory I8. It is preferred, however, that the end portionsl of two adjacent tiles inthe samerrow be engaged and supported by the hanger 4I, as shown in the drawings. When the tiles are so-laid, engagement is had only between the flange 45 of the hanger member 4I andthe end cut-away portions 3l, 33 of adjacent refractries, and between the lugs 46 and the end grooves 21, 29. The flange thus functions to lprovide the necessary vertical support for the associated groupv of refractories I8, the weight of the latter being transmitted to the associated horizontal frame member I2 by the hook 42'and pad 4,4 of the hanger 4I'.

Means are provided for retaining the remaining refractories I8 of the group or section supported by the hanger 4I in proper vertical alinement to prevent inward bulging of the wall. An auxiliary hanger member, indicated generally by reference numeral 5I, is provided foreach section of refractories I8 supported by a hanger member 4I. Each of the auxiliary hanger members 5I (Figs. 2 and 5) comprises an elongated channel member having a main body portion 52, a pair of out-v wardly extending, parallel flanges 53, and la hook member 54 extending upwardly therefrom and formed integrally therewith. The upper and lower ends of the body portion 52 terminate in transversely spaced, forwardly extending pads 55. V An auxiliary hanger member 5I is removably mounted upon a horizontal frame member I2 in vertical alinement with each of the main hanger4 members 4I. The upper end of the hook member 54 o f the auxiliary hanger 5I engages within the groove I4 in the forward surface of the horizontal frame member I2, with the upper pair lof pads' 55 being disposed within the lower margirial groove I6 in the rear surfaceof the frame The lower pair of pads 55 engages within the upper marginal groove I5 of the next lower horizontal frame member I2 and on either side of the hook 42 of the next lower main hanger A plurality of cross pieces 56 are disposed in suitable recesses provided in the flanges 53 of the auxiliary hanger member 5I and are rigidly secured thereto in any desired manner.' The cross pieces 56 are vertically spaced from each other a distance equal to twice the height of the refractories I8.

A horizontally disposed retaining member, indicated generally by reference numeral 6I, is adapted to be' mounted upon eac-h of the cross pieces 56. Each of the retaining members 6I (Figs. 2 and 6) terminates at its rear end in a downwardly extending flange portion 62 which engages behind the associated cross piece 56, the main body portion of the retaining member 6I extending between the flanges 53 of the auxiliary hanger member 5I. The forward end of the retaining member 6.I comprises a horizontally disposed shelf 63 .which terminates at its outer endl in spaced, vertically disposed flanges 64 extending above and below the shelf 63. The retaining member 6I is of such length that the rear surfaces of the flanges 64 will engage the rear surfaces of the grooves v26 and 28 in the associated row, it is not essential to have a retaining member 6I disposed between the next two lower yrows of refractories. In other words, it is only necessary to employ retaining members/in the joints between every other` row of tiles, as shown in Fig. 1. It will be seen that the central cut-away portionsl 32 of the refractories I8 provide clearance for the shelves 63 of the retaining members the section, as shown at the top of Fig. 2. In

order to reduce the weight of the auxiliary hanger member 5I, the -flanges 53 are cut away adjacent the lower end thereof, and the lower retaining member 6I is supported and held against forward 2 transverse movement by the main hanger member Ii I. k'Ihis is accomplished'by'providing a rearwardly extending shoulder 65 at the upper end oi the main hanger member di (Figs. 2 and '7). The

shoulder 65 is disposed in vertical alinement with 3 the cross pieces 56, and the rear flange 62 of the associated member 6I engages this shoulder in the same manner as the other members 6I engage the cross pieces 56. i

arrangement has theadditional advantage 5 of enabling two upper rows of refractories I8 to be added to the top of the wall with the use of only one member 4I and one member 6I per section or group of refractories, while eliminating the necessity of employing an.l additional auxiliary hanger member 5I. The wall may thus be built `un abovethe top horizonta1 frame or. supporting member I2 so as to afford complete protection for the latter. In order to provide for vertical expansion of the wall, a suitable high temperature resistant material is interposed betweenthe lower refractories of each section or group and the upperrefractories of the next lower section, to provide an expansionioint 66 (Fig. 2). This material will completely ll the adjacent grooves in the refractories and entirely cover the forward end ofthe main hanger members 4 I. i

After'allof the -refractories or tiles I8.have been laid toprovide the inner portionofthe wall, in thefmanner above described, the pace betweenLthe rearwsurfaces of the refrac ories and #the .forward surfacesof the horizontalV frame mem-bers `I2 is substantially lled with blocks 6l of anysuitable heat resistant or insulation material. Y As will be seen inthe left hand portion of Fig. 1the insulation blocks 67 are of slightly less length than the refractories I8, so that they will nt between adjacent vertical rows of hanger members di and retaining members Si. The spaces between the `insulation blocks @l and all spaces extending rearwardly from the front surfaces of the horizontal frame members i2 and the auxiliary hanger members di are then `filled with a suitable plastic insulationmacontinuous sheet of insulation which terminates at its rear surface slightlyto'the rear of the rear surfaces of the horizontal frame; members i2.

A plurality of vertically extending plates 59 1I centrally disposed in the main body portion 52 thereof. Each of the apertures 1I is provided with a semi-circular, cut-away portion or extension in its lower edge. A bolt 12 is adapt- Ved to be inserted into each of the apertures 1I from the rear of the wall, the inner head of the bolt being narrower in width than the main portion oi' the aperture 1I. When the bolt 'l2 rests upon the lower surface of the aperture 1i, however, the lower portion of the head thereof engages against the front surface of the body portion 52 of the auxiliary hanger member 5I. Elongated, vertically disposed outer batten strips 13 having suitable longitudinally spaced apertures therein are then mounted upon the plurality of bolts 12, Suitable nuts 'I4 are screwed` upon the bolts 'l2 to draw the batten strips 'I3 tightly against the casing plates 69 to force the latter into rigid contact with the outer surfaces of the` horizontal frarme mem-bers I2. Additional bolts 'I2 may Valso be disposed through the associated aperture I1 in the` horizontal frame members I2. With thislarrangement, and .since an excess of plastic insulation material 68 height of the furnace wall and of a wid-tli substantially equal to the distance between center lines of. adjacent auxiliary hanger members 5I,

as shown in Fig. l, the plates 69 may be any suitable multiple of such width and any desired fractional part of such length.

The modified construction disclosed in Figs. 8

f .to 12 is substantially similar to that hereinbefore described, with lthe primary exception that the outer metal protective plates 69 of the wall of Figs. 1 to '7 are eliminated. To accomplish this result, while providing a furnace wall with an outer surface having finish characteristics, the

, auxiliary hanger members 5I of thejwallof Figs.V

1 to7 have been altered in construction, .and

the shapes of the main refractoryrsupporting -hanger membersV di and the retaining members 5 cation, and are secured tothevertical `frame membersv il. by means oi'boltsv I3. The .frame members 82 are each provided with a centrally disposed, longitudinally extending recess 8d in the inner surface thereof (Fig. 9), and lon tuterial 6d. The plastic material 63 thus forms'a 70 gi dinally extending, marginal recesses 85 and E6 along `the upper and lower edges.

vA` plurality of main refractory supporting hanger members, indicated generally by reference numeral 9i, are provided which are idenare then mounted at the rear of the wall to pro- 75 tical in function and Similar in construction to vin Fig. 10.

the main hanger members 4 I Each of the main hanger members 9| (Figs. 9 and 12) comprises a main body portion which is disposed transversely of the wall and terminates at the rear upper` end thereof in a vertically flanged pad 92. The

rear edge of the hanger member 9| is cut away- I at 93 adjacent and below the pad 92, and ter'- minates at its lower end in a rearwardly extendingpad 94. With such configuration, the un- ;der surface of the upper pad 92 is adapted to clearance for the upper part of the .frame member 82. At its forward end, the hanger member 8| is provided with a forwardly extending, horizontal shelf 95 which terminates in a vertical flange 96 extending above and below the shelf 95'. The upper, rearwardly extending stud 92 of the member 9| is provided with vertical flanges 91 which protrude laterally therefrom for a purpose to be later more fully described.

An auxiliary hanger member, indicated generally `by reference numeral |0|, is removably mounted. upon a horizontal frame member 82 in vertical alinement with each of the main hanger members 9| in similar manner to the positioning of the hanger members 5I of the construction of Figs. 1 to 7. Each-of the-auxiliary hanger members |0I (Figs. 9 and 10) comprises an elongated vmember' having an imperforate base or back portion |02, a pair of outwardly and forwardly extending, parallel flanges |03, and a hook member |04 extending upwardly therefrom, the members |02, |03 and |04 being formed integrally with each other. The upper end of the hook member |04 engages within the groove 84 of the horizontal frame mem- -ber 82 (Fig. 9), with the upper vend of the base member |02 being disposed within the lower marginal groove 8:6 in the rear surface of the frame members. The lower end of the plate or base member |02 engages within the upper marginal groove 85 of the Anext; lower horizontal frameA member 82. The parallel flanges |03 terminate vshort `of the ends ofthe base member |02 to permit such enga-gement of the latter with the associated recess in the horizontal frame member 82. Each of the flanges |03 is provided with a plurality of laterally and inwardly extending lugs |08 spaced vertically from each other a distance equal to twice the height of the refractories I8. The lugs I06`on'the two flanges I03are'disposed in opposite relationship to each -other as shown Each flange |03 terminates at its lower end in an inwardly extending lug |01 which is similar to the lugs |06. Inassembled position, the-fiangesl91 of the main hanger members 19| engage behind the lugs |01 on their associated ,fauxiliary hanger members IOI. Thus,

, while the vertical component resulting from the weight of the refractories I8 supported by a main heat more effectively to the metal frame work y of the retaining members |II (Figs. 8, 9 and hangermember 9| is transmitted thereby to the associated horizontal frame member 82, part of' the horizontal component thereof is transmitted to the frame member 82 by the pad 94 and the remainder is transmitted by the flanges 91 of .the pad 92 to the lugs |01 of the associated aux` iliary hanger member I 0I. f This arrangement has theadvantage over that disclosed in Figs. 1l to 'Zofentirely eliminating any possibility of hot spots in the rear surface of the wall due to the transmission of heat thereto by the main hanger members. 9|, the latter distributing the 11') terminates at its rear end -in a vertically disposed pad |I2 having a. horizontally disposed shelf portion I3 formed at the upper end thereof. The pad |I2 is adaptedto be positioned behind the associatedlugs I 08 of the auxiliary hanger member IOI, and the shelf I I3 rests upon the upper surfaces of the lugs I 06 (Fig. 9) to- V maintain the retaining member inproper position. The forward end of the retaining member III comprises a horizontally disposed shelf II4 which terminates at its Outer end in laterally spaced, vertically' disposed anges IIE extending above and belowihe shelf I I4. These retaining members III function in identical manner to the retaining members 6I of the construction illustrated in Figs. 1 to '1.

It will be readily apparent that the refractories I8 are supported and maintained in proper position by the members 9|, |0I and ||I.in the same manner as bymeans of the members 4I, 5| and 6I. After all of the refractories or tiles I8 have been laid to provide the inner portion of the wall, in'the manner hereinbefore described,

the space between the rear surfaces of the refractories and the forward surfaces of ,the horizontal frame members 82 is substantially lled with blocks II1 of any suitable heat resistant or insulation material, which are substantially identical to the blocks 61. Sincethese insulation blocks are wider than they are high, it is readily apparent that they may be inserted between adjacent auxiliary hanger` members IOI with their longest dimension disposed vertically, and then rotated through to bring them into proper position. The-blocks I1 maythus be stacked one upon the .otherfbehind the 'refractories I8, as shown in Figs. 8 and 9. The spaces between the insulation blocks II1, those'surrounding the main body portions of the hanger members 9| and retaining members III, and all spaces extending rearwardly from the blocks. 61 to the rear surfaces of the horizontal frame members 82 and, the auxiliary hanger members |0I are then lled with a suitable hard, weather-proof plastic any` desired exterior finish, such as paint or the like, applied thereto. The appearance of the exterior of the furnace wall may thus be greatly enhanced, while this modified construction eliminates the necessity of employing the outer metal plates 69 used in the wall of Figs. l to 1.

Referring to Fig. 8, it will be noted that the marginal flanges of the vertical members II and |0| constitute retaining means for the plastic material |I8.

From the above description, it will be clearly understood that the complete wall of either modied construction herein disclosed may be assembled Vor constructed from the rear thereof, or from the exterior of the furnace.v Another important advantage of -this furnace wall is that the separate parts thereof, namely the metal frame work, the refractories, and the insulation material, may be separately and successively erected or assembled. This enables the iron workers to erect the metal frame work entirely independently of any further work vto be done on the furnace wall. The tilesetters may then, at any subsequent time, come in and lay the refractories l8,including the insertion or placing of the members 4I and 6l or 9| and lll. After this part of the job has been completed, the insulation men may lay the blocks 61 or H1 and apply the insulation material 68 or the plastic material H8. 'I'he use of the casing plates 69 will necessitate the return of the metal workers to complete the construction of the wall, but the modified structure illustrated in Figs. 8 to 12 may be completed in separate, successive steps by dierent groups of workmen entirely'independently of each other.

n In like manner, if it becomes necessary to repair any particular section or sections of the instant wall, such sections may be readily removed and replaced from the exterior of the furnace. This has the material advantage of eliminating the necessity of 'the usual delay attendant upon cooling down of the furnace when any repairs to the walls are necessitated. In addition to being relatively inexpensive in construction, the instant wall has extremely low heat transfer characteristics, while maintaining all the advantages of a hard refractory wall. The usual hot spots to be found in prior art walls are completely eliminated, substantially all air spaces within the wall are filled, and the amount .of metal employed and its contact with the refractories forming the inner portion of the wall are reduced to a minimum.V

It is thought that the invention and many of its attendant advantages willbe understood from the foregoing description, and it will be apparent that various changes may be-made in the form,

construction and arrangement of the parts with- `mounting a plurality of vertically disposed, laterally spaced metal members thereon, subsequently mounting hangers on said frame and said members and laying a plurality of .refractories from the exterior of the furnace by supporting the `same on said hangers to form the inner portion-of the wall, and subsequently laying a plurality of insulation blocks between said hangers in engagement with .the rear surfacesof said refractories and` filling substantially all air spaces in the wall and covering said blocks with an excess 'of plastic material.

2. 'I'he method of making a solid, relatively thinfurjiace wall, comprising laying a plurality of refractory bricks to form the inner portion of the wall, laying a.plura1 ity of blocks of insulation material against the rear surfaces of said bricks, applying an excess of plastic-insulation material to the rear surfaces of said blocks, and forcing an outer casing'against the rear surface of said plastic material to fill substantially all air porting and retaining members extending rearwardly therefrom, laying a plurality of blocks of insulation materialagainst the rear surfaces of said bricks between said supporting and retain- 5 ing members, applying an excess of plastic insulation material to the rear surfaces of and between said blocks to surround said supporting and retaining members, and forcing an outer casing against the rear surface of said plastic 10 material to ll substantially all air spaces in the wall therewith. 4. The method of2 constructing a furnace wall, which comprises erecting a skeleton metal frame and mounting a plurality of vertically disposed, laterally spaced metal members thereon, subse- 1 quently mounting supporting and retaining members on said' frame and said spaced metal members and laying a plurality of refractories or` refractory bricks from the exterior of the furnace by supporting the same on said supporting members to form the inner portion of the wall, and subsequently laying a plurality of 'insulation blocks between said supporting members in engagement with the rear surfaces of said re- 'fractories and lling substantially all air spaces in the Wall and covering said blocks with an excess of plastic material.

5. The method of constructing a furnace wall,

terior of the furnace by supporting the same on said hangers to form the inner portion of the wall, mounting separate means on said frame independently of said hangers in such a manner as f to engage a small portion of yeach of therefractories not engaged by said hangersto positively retain the latter refractories in proper alinement, and subsequently laying a plurality of insulation blocks between said hangers in engagement with the rear surfaces of said refractories and filling substantially all air spaces in the wall and covering said blocks with an excess of plastic material.

6. The method of constructing a furnace wall, comprising erecting a skeleton metal frame, mounting main hangers and associated auxiliary hangers *on said frame in substantial vertical alinement with each other, laying a plurality of refractories from the exterior of the furnace by the inner portion of the wall, said main hangers and associated auxiliary hangers being mounted on said frame in such a manner that the vertical component resulting from the weight of the refractories supported by the main hangers is transmitted to the metal frame, and the horizonand subsequently laying a plurality of insulation .blocks between said hangers in engagement with the rear surfaces of said refractories and filling substantially all air spaces in the wall and covering said blocks with plastic material.

7. 'I'he method according to claim 6, which comprises mounting retaining members on said 'auxiliary hangers, in such a manner as to engage v a small. portion of each of the refractories not engaged by said main hangers to positively re- -tain these refractories in proper alinement.

, LOUIS H. HOSBEIN.

supporting the same on said hangers to form` tal component thereof transmitted partly to the metal frame and partly to the auxiliary hanger, 

